Defender 90 - 6.0l LS V8 and 6l80 conversion.

Defender 90 - 6.0l LS V8 and 6l80 conversion.

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Psimpson7

Original Poster:

1,071 posts

240 months

Friday 30th December 2016
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Done a little bit more.

Replacememt gear cable turned up today from Lokar (Excellent service)



This one works perfectly:







Also sorted out the upper radiator mounts.





Interior progress:



Fuel pressure regulator also arrived along with a heap of fittings.



Will try and get some more done tomorrow. smile


Psimpson7

Original Poster:

1,071 posts

240 months

Friday 6th January 2017
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Done a little bit more as stuff arrives.

Fuel lines done including the bypass regulator at the outlets of the rails into the return line. I have an inline filter after the pump as well in the supply line.






Jimmy Recard

17,540 posts

178 months

Friday 6th January 2017
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This looks like a great build. I'll be following it

OzzyR1

5,694 posts

231 months

Friday 6th January 2017
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What a good read and a great project, will be following with interest.

Out of curiosity, why was that Holden written off?

Psimpson7

Original Poster:

1,071 posts

240 months

Monday 9th January 2017
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It had a hit dead on the end of the chassis rail on the left hand side. It basically collapsed the entire rail back to just in front of the suspension pick up. There was a few bits of other superficial damage. It is my understanding that it was actually a police car.



Most of the panel work refitted. Starting to look a lot more complete now. Sorry for the rubbish pictures.








Edited by Psimpson7 on Monday 9th January 01:10

Psimpson7

Original Poster:

1,071 posts

240 months

Monday 9th January 2017
quotequote all
couple more pics showing the air intake roughly set up. Need to feed both rocker breathers into this between the MAF and TB. I have a 3/8 aluminium barb which I will fit into the aluminum joiner tube that connects the 45 and 90 degree hoses




eliot

11,361 posts

253 months

Monday 9th January 2017
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Judging by the colour of the chassis - is that air filter going to keep mud and dust out of the engine?

Psimpson7

Original Poster:

1,071 posts

240 months

Monday 9th January 2017
quotequote all
Chassis is galvanized so that doesn't help the colour!

It's probably not the ideal filter but it will do while I check it all works to start with. I can change it again afterwards if I find a suitable airbox that will fit

PugwasHDJ80

7,522 posts

220 months

Monday 16th January 2017
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oh i love this- i'm trying to find a picture of my portal buggy

What are you using to reprog the ECU to remote VATS etc, and how did you source a mpa for the 6L80e- are they as twitchy to programming as i've read?

PugwasHDJ80

7,522 posts

220 months

Monday 16th January 2017
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ps ignore my last- just found the reprog post.

you need an X-eng handbrake!


Psimpson7

Original Poster:

1,071 posts

240 months

Tuesday 17th January 2017
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Hit an issue now. I have it turning over (Not trying to start it yet as no fuel) but I noticed that it would turn over irrespective of the gear lever position which as I have the loom set with a Neutral / Park start only inhibitor it shouldn't

I plugged in the gear indicator and irrespective of what position the lever was in it always displayed 'N'

I spoke to Speartech and after doing so, drained and removed the sump. When I got it off I noticed that when I refitted the TCM I missed lining up the selector shaft nub with the IMS (Internal Mode Switch) on the TCM.

I have corrected that and now I get the correct display for Park but all other positions still show 'N'

You can just about see the issue in my image below . The silver nub should be meshed with the black plastic fitting which them connects to the white plastic IMS:



Hopefully this is something not too serious. Maybe I damaged the IMS? Just waiting on an update from Speartech to see if they have any more comments.

In the meantime I went back to working on things I am less likely to ruin....

Emissions stuff



Canister fitted in rear wheel arch. This is in front of the wheel on the drivers side. I will make up a guard of some sort to limit the risk of stuff hitting the connections. Hopefully its not supposed to be fitted in a certain orientation.





anonymous-user

53 months

Friday 20th January 2017
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Awesome. Wish I had the skills to contemplate doing something like this.

Psimpson7

Original Poster:

1,071 posts

240 months

Monday 23rd January 2017
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Cheers, some days I wish I had more skills. Normally by then I have gone so far I have no choice but to carry on.

The auto is all back together again now so that's good, Hopefully it all works!

I had been doing some research on how to set up the emissions stuff. I wasn't really sure and confused myself a bit but I think I have it nailed now.

Basically

Tank breather ---> Larger connection of pair on EVAP canister
Smaller connection on EVAP canister ---> Purge valve on Engine
Fuel tank pressure sensor (to read pressure from fuel system - I will probably fit this in the EVAP canister)
Vent valve ---> larger connection on own on EVAP canister
Filter line on Vent valve ----> vents to atmosphere.

When the engine is off this allows the tank to release pressure out of the system via the filter line.
When the engine is running it feeds the tank emissions through the evap cannister, then to the purge valve which when it sees fit releases it into the throttle body.

I also have to change a couple of electrical connectors. The fuel tank pressure sensor plug was wrong. It looked like it should use the identical looking e85 fuel flex sensor type plug so I ordered one of those (I could get this locally so figured it was worth a gamble).

Typically the shape of the plug was very slightly different so I tweaked it with a dremel and file. The pin spacing and height luckily was 100%

I then swapped the plug over.

This is the one that was on the loom.



You can see the sensor in the background.



New connector pins:







Need to change the one on the vent valve section of loom next.




anonymous-user

53 months

Monday 23rd January 2017
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Threads like these pop up occasionally on Pistonheads and they are generally an absolute pleasure to read. This is bloody awesome and goes way beyond anything I would ever contemplate doing using a mechanic, let alone doing it myself. Respect.

triple5

751 posts

144 months

Monday 23rd January 2017
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Great stuff, keep it coming.

Krikkit

26,500 posts

180 months

Monday 23rd January 2017
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Sounds like the emissions rules are pretty strict, how much more is there to include on the car? Does it have to pass to the same standard as the donor?

Psimpson7

Original Poster:

1,071 posts

240 months

Tuesday 24th January 2017
quotequote all
bulldong said:
Threads like these pop up occasionally on Pistonheads and they are generally an absolute pleasure to read. This is bloody awesome and goes way beyond anything I would ever contemplate doing using a mechanic, let alone doing it myself. Respect.
Thanks very much smile

Psimpson7

Original Poster:

1,071 posts

240 months

Tuesday 24th January 2017
quotequote all
Krikkit said:
Sounds like the emissions rules are pretty strict, how much more is there to include on the car? Does it have to pass to the same standard as the donor?
Basically the donor car has to be newer than the car into which it is being fitted and it has to keep all the same emissions stuff as the donor car.

In short its not actually that difficult now I sort of know what I am doing.

Basically it needs 2 cats, Pre and Post cat o2 sensors, and this evap stuff.

I pretty much have all that done now bar a couple of bits of pipe and some a lot of hose clamps!

Not too far off being able to see if it starts now. Couple of things left to do on the fuel system and probably a few other minor bits and pieces.

The last big hurdle will be the exhaust but I think I will get someone to make that for me.

PugwasHDJ80

7,522 posts

220 months

Tuesday 24th January 2017
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Here was mine in build:


Psimpson7

Original Poster:

1,071 posts

240 months

Tuesday 24th January 2017
quotequote all
PugwasHDJ80 said:
Here was mine in build:
Nice. Portals and Jungle trekkers! Looks pretty tall! I am actually thinking of trying to lower mine a bit more